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12

WARNING: 

Before 

operating your machine, 
carefully read and understand 
all safety (Section 1), controls 
(Section 3) and operating 
instructions (Section 4) in this 
Manual, the separate Engine 
Owner’s Manual, and on the 
decals on the machine. 
Failure to follow these 
instructions can result in 
serious personal injury.

INTRODUCTION

Read this 

Operation

 Section and the sepa-

rate Engine Owner’s Manual before you 
start the engine. Then, take the time to fa-
miliarize yourself with the basic operation 
of the tiller before using it in the garden. 
Find an open, level area and practice using 
the tiller controls without the tines engag-
ing the soil (put tines in “travel” setting). 
Only after you’ve become completely fa-
miliar with the tiller should you begin using 
it in the garden.

BREAK-IN OPERATION

Perform the following maintenance after 
the first two (2) hours of new operation 
(see 

Maintenance

 Section in this manual 

and in the Engine Owner’s Manual).

1. 

Change engine oil.

2. 

Check for loose or missing hardware on 

unit. Tighten or replace as needed.

3. 

Check tension on forward drive belt.

4. 

Check transmission gear oil level.

STARTING AND STOPPING 

Pre-Start Checklist

With the spark plug wire disconnected 
from the spark plug, perform the following 
checks and services before each use:

1. 

Read the 

Safety 

and 

Controls

 Sections 

in this manual. Read the separate Engine 
Owner’s Manual provided with the unit.

2. 

Put the wheels in the WHEEL DRIVE po-

sition (wheel pins must be through holes 
in wheel hubs and wheel shaft).

3. 

Check unit for loose or missing hard-

ware. Service as required.

4. 

Check engine oil level. See Engine Own-

er’s Manual.

5. 

Check that all safety guards and covers 

are in place.

6. 

Check air cleaner and engine cooling 

system. See Engine Owner’s Manual.

WARNING: 

GASOLINE IS 

HIGHLY FLAMMABLE AND ITS 
VAPORS ARE EXPLOSIVE. 
Follow gasoline safety rules in 
this Manual (see Section 1) and 
in the separate Engine Owner’s 
Manual.
Failure to follow gasoline safety 
instructions can result in 
serious personal injury and 
property damage.

7. 

Fill the fuel tank with gasoline according 

to the directions in the separate Engine 
Owner’s Manual. Follow all instructions 
and safety rules carefully.

8. 

Attach spark plug wire to spark plug.

Starting the Engine

The following steps describe how to start 
and stop the engine. 

WARNING: 

Do not attempt 

to engage the tines or wheels 
until you have read all of the 
operating instructions in this 
Section. Also, review the safety 
rules in Section 1: 

Safety,

 and 

the tiller and engine controls 
information in Section 3: 

Features and Controls.

1. 

Complete the 

Pre-Start Checklist

 on this 

page. 

2. 

Put the wheels in the WHEEL DRIVE po-

sition (see 

Wheel Drive Pins 

in Section 3 of 

this manual). 

WARNING: 

To help 

prevent serious personal injury 
or damage to equipment:

• Before starting engine, put both

wheels in the WHEEL DRIVE position.
Never have wheels in FREEWHEEL po-
sition when engine is running. When
the wheels are in FREEWHEEL, they do
not hold back the tiller and the tines
could propel the tiller rapidly 
forward or backward.

• Before starting engine, put Forward

Clutch Bail (all models) and Reverse
Clutch Control (Model 6

4

4A only) in

neutral (disengaged) positions by re-
leasing levers.

• Never run engine indoors or in en-

closed, poorly ventilated areas. Engine
exhaust contains carbon monoxide, an
odorless and deadly gas.

• Avoid engine muffler and nearby areas.

Temperatures in these areas may ex-
ceed 150° F.

3. 

Move the Depth Regulator Lever all the 

way down to the “travel” position, so that 
the tines clear the ground.

4. 

Release all controls on the tiller.

5. 

On engine’s with a fuel shut-off valve, 

turn valve to open position, as instructed 
in the separate Engine Owner’s Manual.

6. 

Put ignition switch and/or throttle con-

trol lever located on engine in the “ON”, 
“RUN”, “FAST” or “START” position, as in-
structed in the Engine Owner’s Manual.

7. 

Choke or prime engine, as instructed in 

Engine Owner’s Manual.

8. 

Put one hand on fuel tank to stabilize 

unit when pulling starter rope handle. Then 
use recoil starter to start engine, as in-
structed in the Engine Owner’s Manual. 
When engine starts, gradually move choke 
lever (if so equipped) to “NO CHOKE”, 
“CHOKE OFF” or “RUN” position.

9. 

Use the “FAST” throttle speed setting 

when tilling. 

Fig. 4-1

Wheel Drive Pin

Depth Regulator

Forward

Clutch Bail

Reverse Clutch Control 

(Model 6

4

4A)

SECTION 4:  OPERATION

Summary of Contents for 640C - Tuffy CRT

Page 1: ...engine s exhaust system is equipped with a spark arrester meeting applicable local or state laws if any If a spark arrester is used it should be maintained in effective working order by the operator In the State of California the above is required by law Section 4442 of the California Public Resources Code Other states may have similar laws Federal laws apply on federal lands A spark arrester for ...

Page 2: ...n seek help from the experts Choose from the options below Visit troy bilt com for many useful suggestions Click on Customer Support button and you will get the four options reproduced here Click on the appropriate button and help is immediately available If you prefer to reach a Customer Support Representative please call 1 800 520 5520 The engine manufacturer is responsible for all engine relate...

Page 3: ...igars pipes open flames and sparks away from the fuel tank and fuel container d Fill fuel tank outdoors with extreme care Never fill fuel tank indoors Use a funnel or spout to prevent spillage e Replace all fuel tank and container caps securely f If fuel is spilled do not attempt to start the engine but move the ma chine away from the area of spillage and avoid creating any source of ig nition unt...

Page 4: ...ls by releasing whichever clutch control is engaged Do not attempt to restrain the tiller 15 Do not overload the tiller s capacity by attempting to till too deeply at too fast a rate 16 Never operate the tiller at high trans port speeds on hard or slippery surfaces Look behind and use care when backing up 17 Do not operate the tiller on a slope that is too steep for safety When on slopes slow down...

Page 5: ...AND SHIELDS IN PLACE AND WORKING NEVER ALLOW CHILDREN OR UNINSTRUCTED ADULTS TO OPERATE TILLER SHUT OFF ENGINE AND DISCONNECT SPARK PLUG WIRE BEFORE MANUALLY UN CLOGGING TINES OR MAKING REPAIRS KEEP BYSTANDERS AWAY FROM MACHINE KEEP AWAY FROM ROTATING PARTS USE EXTREME CAUTION WHEN REVERSING OR PULLING THE MACHINE TOWARDS YOU Operating Symbols Varioussymbols shownhere withworddescriptions maybeuse...

Page 6: ...your local dealer or the factory items are missing or dam aged NOTE Use the screw length template Fig 2 1 to identify screws Loose Parts List Qty Description 1 Handlebar Support see A Fig 2 2 1 Handlebar Assembly see K Fig 2 2 Hardware bag contents 4 Hex hd screw 5 16 18 x 1 1 2 2 Hex hd screw 3 8 16 x 3 4 2 Flat Washer 3 8 4 Split lock washer 5 16 4 Hex nut 5 16 18 2 Hex locknut 3 8 16 Model 644A...

Page 7: ...in Wheel Drive Pins in Section 3 STEP 4 INSTALL FORWARD CLUTCH CABLE 1 Carefully unwrap the forward clutch ca ble cable without an attached knob from its shipping position and slide the thin ca ble wire T Fig 2 4 into the slot in the ca ble bracket Push the cable connector U Fig 2 4 up through the hole in the bracket until the groove in the connector snaps into place 2 Thread the 10 24 hex nut Z F...

Page 8: ... 8 and Fig 2 9 from its shipping po sition and route it up to the handlebar Be sure that the cable is routed beneath the Forward Clutch Bail 2 Insert the cable CC Fig 2 8 through the slot in the cable bracket and position the flat side of the threaded assembly next to the flat side of the hole Slide the hex nut DD up the cable and tighten it securely 3 Fasten the reverse clutch cable to the left s...

Page 9: ...mage will result if the engine is run with out oil 1 Refer to the separate Engine Owner s Manual for engine oil specifications and capacities 2 With the tiller on level ground move the Depth Regulator Lever FF Fig 2 10 up or down until the engine is level 3 Add motor oil as described in the En gine Owner s Manual 4 Move the Depth Regulator Lever all the way down until the highest notch is en gaged...

Page 10: ...ch Control Model 644A is en gaged Use the FREEWHEEL mode only when the engine is not running In FREEWHEEL the wheel drive pins are placed only through the holes in the wheel shaft not the wheel hubs thus allowing the wheels to turn freely when you manually move the tiller To place the wheels in WHEEL DRIVE or FREEWHEEL 1 Stop engine disconnect spark plug wire from spark plug and allow engine to co...

Page 11: ...nob F Figure 3 4 out The wheels and tines will rotate in a reverse direction 4 Release the control knob to disengage stop the wheels and tines the engine will continue to run DEPTH REGULATOR LEVER This lever G Figure 3 5 controls the till ing depth of the tines Pull the lever back and slide it up or down to engage the notched height settings The travel position highest notch raises the tines appro...

Page 12: ...ng to the directions in the separate Engine Owner s Manual Follow all instructions and safety rules carefully 8 Attach spark plug wire to spark plug Starting the Engine The following steps describe how to start and stop the engine WARNING Do not attempt to engage the tines or wheels until you have read all of the operating instructions in this Section Also review the safety rules in Section 1 Safe...

Page 13: ...n on the handlebars to try to make the tiller till more deeply This prevents the wheels from holding the tiller back and can allow the tines to rapidly propel the tiller forward which could result in loss of control property damage or personal injury 5 For reverse motion of the wheels and tines Model 644A only a Look behind and exercise caution when operating in reverse Do not till while in revers...

Page 14: ...hrottle lever at a speed to give the engine adequate power and yet allow it to operate at the slowest possible speed at least until you have achieved the maximum tilling depth you desire Faster engine speeds may be desirable when making final passes through the seedbed or when cultivating Selection of the correct engine speed in relation to the tilling depth will ensure a sufficient power level to...

Page 15: ... debris It may be necessary to remove the debris by hand a pocket knife will help you to cut away the material Be sure to stop the engine and disconnect the spark plug wire before clearing the tines by hand WARNING Before clearing the tines by hand stop the engine allow all moving parts to stop and disconnect the spark plug wire Remove the ignition key on electric start models Failure to follow th...

Page 16: ...wo or more people are needed to do this The ramps must be strong enough to support the combined weight of the tiller and any handlers The ramps should pro vide good traction to prevent slipping they should have side rails to guide the tiller along the ramps and they should have a locking device to secure them to the vehicle The handlers should wear sturdy footwear that will help to prevent slippin...

Page 17: ...f a cover is leaking check for loose screws If the screws are tight a new gasket or oil seal may be required If the leak is from around a shaft and oil seal the oil seal probably needs to be replaced See your authorized dealer or contact the factory for service or advice IMPORTANT Never operate the tiller if the transmission is low on oil Check the oil level after every 30 hours of operation and w...

Page 18: ...of the transmission 6 Reinstall the wheel 7 Install a new gasket do not reuse old gasket and reinstall the transmission cov er 8 Refill the transmission using GL 4 gear oil SAE 85W 140 or SAE 140 9 Refill the engine with motor oil and re plenish the fuel tank with gasoline BOLO TINES The bolo tines will wear with use and should be inspected at the beginning of each tilling season and after every 3...

Page 19: ...screw D c Unhook the top of the spring from the Forward Clutch Bail d Use pliers to prevent the adjuster B from turning and turn the slotted screw lo cated inside the spring clockwise viewed from operator s position to increase ten sion on the spring Turn the screw counter clockwise to decrease tension Once adjusted reattach the spring to the For ward Clutch Bail e RepeatSteps2and3tore measurethe ...

Page 20: ...the bracket 7 Measure the gap by repeating Step 3 Readjust as needed by repeating Steps 5 and 6 8 Reinstall the belt cover Replacement Belt Information If the drive belt needs to be replaced see your local authorized dealer or refer to the Parts List for ordering information Use only a factory authorized belt as an over the counter belt may not perform satis factorily The procedure requires averag...

Page 21: ...s on the machine the governor controls the maximum safe operating speed to protect the engine and all moving parts from damage caused by overspeed Authorized service shall be sought if a problem exists CARBURETOR GOVERNOR CONTROL ADJUSTMENTS The carburetor was adjusted at the factory for best operating speed Refer to the En gine Owner s Manual for any adjustment information or see your authorized ...

Page 22: ... oil level see Engine Owner s Manual Engine does not shut off 1 Misadjusted throttle control or ignition switch 1 See Engine Owner s Manual or Engine Service Dealer Wheels and Tines will not turn 1 Improper use of controls 1 Review Sections 3 and 4 2 Worn broken or misadjusted drive belt s 2 See Checking Drive Belt Tension Section 5 3 Internal transmission wear or damage 3 Contact local dealer or ...

Page 23: ...119 Lock Washer 5 16 10 GW 55013 1 Hood Bracket Left Hand 11 GW 55013 2 Hood Bracket Right Hand 12 GW 55015 Drag Bar 13 GW 55018 Depth Regulator Lever 14 686 04043 Tine Hood Assembly A 686 04041 Tine Hood Assembly B 15 GW 55088 Bushing 16 GW 9384 Spring Depth Regulator 17 GW 9534 Spacer 18 710 04048 Hex Hd Flange Screw 5 16 18 x 1 19 618 04254 Transmission Assembly A 618 04046 Transmission Assembl...

Page 24: ...24 MODELS 640C 644A 5 10 2 5 15 1 12 16 21 3 13 20 4 17 11 22 7 25 8 6 23 14 18 18 7 9 ...

Page 25: ... x 1 2 6 710 3008 Screw Hex 5 16 18 x 3 4 7 712 3009 Hex Lock Nut 5 16 18 8 786 04188 Handlebar Support 9 GW 55043 Lower Handlebar 10 786 04200 Panel 11 GW 55044 Tab Conduit Mount 12 GW 9855 Screw 10 24 x 2 13 725 0157 Cable Tie 14 736 3050 Flat Washer 3 8 15 732 04040 Bracket Reverse Clutch Cable B 16 732 04185 Spring Forward Clutch 17 710 0106 Hex Hd Screw 1 4 20 x 1 1 4 18 710 0216 Screw Hex 3 ...

Page 26: ... 5 4 6 6 8 8 9 10 10 12 3 14 13 11 7 Included with transmission when purchased as an assembly only Remove and discard when installing the transmission on tiller REF NO PART NO DESCRIPTION 1 GW 9727 Plug Transmission Oil Fill 2 710 04049 Hex Hd Flange Screw 5 16 18 x 5 8 Gr 5 3 736 0119 Lock Washer 5 16 4 1918377 Rear Cover Transmission 5 1916641 Front Cover Transmission 6 GW 50032 Gasket Housing C...

Page 27: ...66 2 Shim 0 030 thick GW 1166 3 Shim 0 015 thick GW 1166 4 Shim 0 010 thick GW 1166 5 Shim 0 005 thick 4 GW 1086 Bronze Bushing 5 711 04088 Wheel Shaft A 711 04092 Wheel Shaft B 6 GW 9305 Key Hi Pro 1 4 x 1 7 GW 1132 2 Spacer 8 1904278 Worm Gear Wheel Shaft 9 711 04078 Tiller Shaft 10 GW 1104 Woodruff Key 11 1916542 Worm Gear Tiller Shaft 1 2 3 4 7 7 4 3 2 FRONT 9 5 6 10 11 8 A For Model 640C B Fo...

Page 28: ...LS 640C 644A 9 24 28 20 30 25 27 1 1 11 5 17 19 28 1 12 10 14 16 38 32 31 3 2 7 8 37 19 39 33 4 38 34 FORWARD CLUTCH CABLE 35 41 28 24 22 22 24 6 13 21 28 16 29 18 36 23 40 REVERSE CLUTCH CABLE 15 28 26 42 43 ...

Page 29: ...4 x 1 B 20 710 0237 Hex Hd Screw 5 16 24 x 5 8 21 710 0376 Hex Hd Screw 5 16 18 x 1 22 710 04049 Hex Hd Screw 5 16 18 x 5 8 23 710 0347 Hex Hd Screw 3 8 16 x 1 3 4 24 710 0599 Screw Self Tapping 1 4 20 x 1 2 25 710 3103 Hex Hd Screw 5 16 18 x 2 B 26 712 3000 Lock Nut 3 8 16 27 712 3009 Lock Nut 5 16 18 28 736 0119 Lock Washer 5 16 29 750 0535 Spacer 380 ID x 625 OD x 21 30 736 3090 Flat Washer 31 ...

Page 30: ...ht Side B 734 04162 Wheel Tire Ass y Left Side Only A 8 734 04161 Wheel Tire Ass y Right Side Only A 9 GW 9380 Clevis Pin 312 x 1 3 4 10 GW 9338 Hair Pin Cotter GW 1901 Bolo Tine Replacement Set Incl eight right hand tines eight left hand tines and required hardware A B 9 9 10 7 8 3 2 TINE SHAFT 1 4 5 1 3 3 5 7 2 A For Model 640C B For Model 644A Hold Tines With Blunt End Toward You RIGHT HAND TIN...

Page 31: ...31 NOTES ...

Page 32: ... commercial institutional industrial rental or demonstrator purposes the warranty COMMERCIAL on the tiller is limited in duration to 90 days from the date of purchase USE WARRANTY This warranty does not apply to parts that have been damaged by accident alteration misuse abuse neglect improper maintenance vandalism theft fire water or damage because of peril or other natural disaster HOW TO OBTAIN ...

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